Protective binding layer

ABSTRACT

The embodiments of the present invention are directed to a synthetic turf system that includes a hardened layer adjacent or immediately adjacent to a backing layer and also includes artificial turf fibers that extend from the backing layer and the hardened layer. The hardened layer may have been hardened by applying a hardening agent to a layer comprising felt or felt-like material. The layer comprising felt or felt-like material has characteristics that improves wicking and consistency of the hardening agent as compared to the backing layer. The hardening agent may also reach or apply to a backing sheet of the backing layer. Other embodiments and variations of embodiments are also contemplated.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. application No. 62/247,708 filed on Oct. 28, 2015, U.S. application No. 62/238,672 filed on Oct. 7, 2015, and U.S. application No. 62/213,404 filed on Sep. 2, 2015, the content of each of which is expressly incorporated by reference thereto.

FIELD OF INVENTION

The present invention is generally directed towards a synthetic turf system, and is more particularly related to using a polymeric hardening coating material on the synthetic turf field in order to create a protective layer on the synthetic turf field to thereby prevent penetration and damage of the synthetic turf backing system. The invention is further directed towards a method of making the artificial turf field by using the polymeric hardening coating material.

BACKGROUND OF THE INVENTION

Artificial turf structures are well known in the art. Such a structure generally comprises a backing layer with an upper surface provided with a plurality of grass-like fibers of a selected length. The fibers extend upwardly from the upper surface and an infill layer of granules (e.g., crumb rubber, sand, cork, etc.) disposed between the fibers. The backing layer may be composed of a sheet of polypropylene material such as, for example, a non-woven fabric. Extending upwardly from the upper surface of the backing layer, a large number of upstanding fibers are present. These fibers are tufted through the backing layer and may be held in place by, for example, using latex or polyurethane.

Synthetic turf systems are often times used to replace natural grass fields for many reasons such as costs, practicality, or performance. The more desirable synthetic turf systems on the market incorporate an infill material between blades of synthetic turf fibers. The infill material enables a variety of features and characteristics to be imparted to the actual playing surface, while simultaneously enabling the synthetic fibers to retain a grass-like appearance. Thus, synthetic turf systems can stand up to heavy use, require much less costly maintenance, eliminate the use of herbicides and pesticides, provide improved drainage and remain open for play even after a rain event, display improved resiliency and reduce the incidences of injuries. Other advantages can be imparted to the synthetic turf surface, while maintaining an appealing appearance at the same time.

One particular function of the infill in some synthetic turf systems is as a stabilizing force for the synthetic grass-like filament fibers. The synthetic fibers in infill-type synthetic turf systems are relatively long (e.g., as compared to systems having no infill), for example, between 1½-2½ inches long so as to provide optimum surface “feel” and appearance. Therefore, in order to maintain these types of fibers in a substantially upright orientation, the infill material has been applied up to a pre-determined depth or thickness relative to the height of the fibers. In turn, the infill provides amongst other things a base for the synthetic filament fibers. The infill layer also provides other functions such as protecting the backing from damage.

On an artificial turf field, there are areas that are considered to be particularly of high-use zones. Especially on baseball fields (e.g. batters boxes, pitcher's mound and sliding zones), lacrosse fields (e.g. goal crease) and soccer fields (e.g. corner kick and penalty spot). It is quite typical for those areas to get easily worn out to the point where the infill is no longer in place due to migration and use, and the backing is subsequently exposed. Once exposed, the backing is susceptible to being punctured by a cleat thereby creating permanent damage to the field surface.

When the backing layer is damaged, one known solution has been to repair the field by cutting and removing that section of the field and installing a new section. This can be a very expensive process. Another general solution has been to use Velcro seams such that it is possible to replace worn-out areas on the field themselves with new pieces and new Velcro loops. The disadvantages to this, however, are that the users have to perform the work themselves and the extent and the severity of the work is not always known beforehand. Further added to these disadvantages, Velcro seams are not as solid as a permanently stitched, or even bonded seam. They can present more of a trip hazard than traditional seaming methods.

A third prior solution has been to tuft the synthetic turf carpet with three or more primary backing layers to theoretically provide more stability or puncture resistance to the primary backing. This method, however, does not eliminate the cleat penetrating all the way down to and past the lowest situated backing layer.

As such, in light of the obstacles faced thus far generally in the manufacturing of a stable synthetic turf field with an efficient physical capability that can withstand penetration and damage caused by extreme force inflicted by individual users, there still remains an unmet need for a synthetic turf field and a method of making the same that can address and provide a solution to the above-mentioned problems.

It is therefore an object of the present invention to overcome these and other issues associated with conventional synthetic turf systems. In consequence of this, the present embodiments of the invention now provide such a novel solution to this problem, and others evident to those of ordinary skill in the art, and as such, satisfy the need of extending the durability of the synthetic turf field. These and other objects will become apparent to one of ordinary skill in the art in light of the specification, claims, and drawings appended hereto.

SUMMARY OF THE INVENTION

It is contemplated by the embodiments of the present invention to provide a synthetic turf system that satisfies the hereinabove presented needs and requirements.

According to a first aspect, in one embodiment of the synthetic turf system of the present invention, the synthetic turf surface comprises a flexible backing layer, an infill lying above the backing layer and including a ballast layer comprising infill material having therein a hardening material. The hardening material coats at least a portion of the ballast layer and forms a rigid and hardened layer that protects the backing layer from damage. A plurality of grass-like artificial filaments are attached to the backing layer, wherein the artificial filaments extend upward from the backing layer over the infill material.

In one embodiment, the hardening material of the ballast layer is a polymeric acrylic coating material.

In another embodiment, the hardening material of the ballast layer is a polymeric polyurethane.

In any of the embodiments, the purpose of the polymeric hardening material is to provide additional strength to the synthetic turf surface, wherein the hardening material is water-based, and selected areas of the field are installed with the hereinabove described synthetic turf system.

In any of the embodiments, the water-based hardening material is cured by coalescence where first the water, and then the trace, and/or coalescing solvent evaporate and draw together the binder particles and fuse them together into an irreversibly bound polymer network structure.

In some embodiments, the water-based hardening material may be a one-component or multi-component material.

In any of the described embodiments, the ballast layer of the infill preferably comprises sand, rubber, rock, plastics, cork, styrene, calcined clay, used tires, neoprene, a combination thereof, or any like granular materials.

In one embodiment of the present invention, the plurality of grass-like filaments comprise a material that is polyethylene, nylon, olefin or a combination thereof.

In another embodiment, the backing layer comprises a material that is polypropylene, a geotextile material or a combination thereof.

It is further an object of the present invention to provide a method of making a synthetic turf field. The method comprises installing the synthetic turf field having a backing layer, an infill, a plurality of grass-like filaments attached to the flexible backing layer. After installing the synthetic turf, a ballast layer of the infill is applied onto the synthetic turf field. This is followed by applying a hardening material into the ballast layer of the infill, thereby creating a rigid and hardened layer that protects the backing layer from damage. Finally, sand, rubber, rock, plastics, cork, styrene, calcined clay, used tires, neoprene, a combination thereof, or any like granular materials are applied on top of the rigid and hardened layer constituting the remainder of the infill.

In accordance with yet a further principle of the present invention, a synthetic turf surface is contemplated comprising a flexible backing layer comprising a middle felt layer, wherein the middle felt layer is inserted between at least two layers of the backing layer. A top side of the backing layer is treated with a one-hundred percent solids, semi-flexible multi-part epoxy coating that reaches at the least the middle felt layer. As such, application of the multi-part epoxy coating stabilizes and protects the backing layer from damage. The multi-part epoxy coating is preferably resistant to hydrolysis and moisture-induced degradation. The synthetic turf-surface may further have an infill layer lying above the backing layer comprising infill material and a plurality of grass-like artificial filaments attached to the backing layer, wherein the artificial filaments extend upward from the backing layer over the infill.

In accordance with another preferred embodiment of the present invention, a synthetic turf system is contemplated. The system may comprise a backing layer comprising a felt layer and a backing sheet. As it would be understood, in this context, the backing layer is being used to refer to a combination of a first layer for providing rigidity and hardening characteristics to the backing layer and a second layer that is a backing sheet, such as conventional backing sheet used in synthetic turf systems. In this context, the term backing sheet is used. In other embodiments, a backing layer and a separate hardened and rigid layer (e.g., hardened felt layer) are mentioned and in those instances, it should be understood that the backing layer does not include felt or hardened/rigid layer.

The backing layer (containing a backing sheet and a felt layer) contains a multi-part epoxy that is hardened to protect the backing layer from damage. The turf systems, when installed, included an infill layer lying above the backing layer and a plurality of grass-like artificial filaments attached to the backing layer and extending upward from the backing layer over the infill layer. It should be understood that other materials with similar characteristics to felt are contemplated.

In one variation of the another preferred embodiment, the backing sheet may be positioned between the infill layer and the felt layer. A multi-part epoxy can be applied to the felt layer as part of the installation process. The epoxy can be applied by flipping the synthetic turf over and applying the epoxy or hardening agent to the felt layer. As a matter of clarification, the synthetic turf includes the grass fibers (and the backing sheet and felt layer) when it is produced before it is flipped over and an epoxy is applied. The application of epoxy is controlled to determine the depth level that the epoxy will reach, which can for example include all or a portion of the felt layer and possibly include reaching the backing sheet.

For example a method of manufacturing may comprise forming a backing layer by attaching a felt layer and a backing sheet together; tufting a plurality of grass-like artificial filaments through the backing layer; flipping over the backing layer with the filaments such that the felt layer faces the direction in which a multi-part epoxy is applied; applying the multi-part epoxy to the backing layer with filaments; hardening the multi-part epoxy in the backing layer; flipping over the backing layer with hardened multi-part epoxy; and dispersing an infill layer on the backing layer with hardened multi-part epoxy.

In some embodiments, the felt layer may be positioned above the backing sheet and the epoxy is applied to the felt layer from the top side of the synthetic turf (the side where the fibers extend).

Other embodiments are contemplated in which a layer is integrated into the synthetic turf that is used to receive and soak with a hardening agent. The layer has sufficient thickness, hardness, and rigidity to provide wear resistance. The layer will have a thickness that will be sufficient for providing such features. The layer will then prevent a high use area from wearing down to a point at which a hole is formed in the backing layer and grass fibers in that location has been detached.

BRIEF DESCRIPTION OF THE FIGURES

The nature and various advantages and exemplary embodiments of the present invention, which will become more apparent as the description proceeds, are described in the following detailed description in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:

FIG. 1 illustrates a side elevation view of the synthetic turf surface in accordance with an embodiment of the present invention.

FIG. 2 depicts an up close view of the artificial turf surface treated with the polymeric hardening coating material in accordance with an embodiment of the present invention.

FIG. 3A depicts a synthetic turf system in accordance with an embodiment of the present invention.

FIG. 3B depicts a synthetic turf system in accordance with an embodiment of the present invention.

FIG. 3C depicts a synthetic turf system in accordance with an embodiment of the present invention.

FIG. 3D depicts a synthetic turf system in accordance with an embodiment of the present invention.

FIG. 4 depicts a synthetic turf system in accordance with an embodiment of the present invention.

FIGS. 5A-5D depict embodiments of hardening performed from a felt layer side.

FIGS. 6A-6D depict embodiments of hardening performed from a backing sheet side.

FIGS. 7A-7G depict to a method of manufacturing a synthetic turf system in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiment in many different forms, there is demonstrated in the Figures, and will herein be described in detail one or more embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention, and should not be intended to limit the invention to the embodiments specifically illustrated. The Figures are provided for illustrative purposes only and are not necessarily drawn to actual scale size or proportion. In some figures, it would be understood that the felt layer is thicker than the backing sheet. The dimensions used would be understood by a person with ordinary skill in the art.

The benefits, advantages and features of the present invention will become more fully apparent from the following inventive embodiments. Now, generally referring to FIGS. 1-2, the synthetic turf system will be described in greater detail referring to the presented numerals. The terms, “artificial” or “synthetic” as used throughout this specification refer to any non-naturally occurring product, and are used interchangeably herein this disclosure.

As illustratively described herein, in some embodiments, as part of the installation, or improvement of a synthetic turf field, a hardening agent is added to the infill layer, such as to a ballast infill layer (e.g., an initial layer that is added to the field to provide upright support to the artificial turf fibers). The hardening agent coats the material in the infill layer (e.g., material in the ballast layer) and after being added, hardens to bind the material together to form a rigid toughened layer that is resistant (substantially resistant) to wear or dispersal from use such as athletic use. The feature can be added to selected areas of a field, if desired, that are high-use areas of the field. The feature can be implemented in areas in order to also provide an additional mechanism for locking the synthetic turf fibers into place. It should be understood that infill is made of loose material or granules that for example provide the similar effect of natural ground. The hardening material when added and activated to be hardened, changes the quality of the infill in the applied area to no longer be loose. In those areas, which can be at a base or ballast layer in which the hardening material is added, the infill is hardened (because the loose material has been bound together using the hardening material). The surface or grip characteristic will therefore also be modified as a result. Loose infill is typically placed over the hardened layer. The hardened infill will be more resistant to wear or dispersal resulting from use when compared to loose infill. In other words, the hardened infill can separate or wear into smaller, loose, granules over time but this transformation will take a significant amount of time as compared to conventional infill that does not contain the hardening material. It should also be understood that a range of coating or saturation is possible. In other words, the hardening material preferably forms a rigid contiguous area (sufficient to protect an area of high use), but it does not necessarily have to be that way in implementation. There can possibly be some mix of different areas and/or some mix of the percentage of the base, or ballast area, that is treated with the material. In other words, loose infill and hardened material can coexist in some mixed fashion if desired. If desired, the entire field can be treated like the ballast layer. The hardened material can provide a safety feature in that, if it is located at a bottom layer, it would then provide automatic protection of the backing when the infill has an unexpected deterioration in an area. The hardened layer will have the characteristic, in which, that layer will be resistant (e.g., will not break or crumble) to the use of cleats, or other footwear on the hardened layer over an extended time frame. The hardened layer will not break down, or substantially break down after several days to months of frequent athletic use over the hardened area (involving direct or indirect contact with the hardened layer).

Starting with reference to FIG. 1, a synthetic turf system 10 of the present invention is shown, including a flexible backing layer 12, and a plurality of grass-like artificial filaments 14 projecting upwardly through a bottom side 16 and upwardly from a top side 18 of the backing layer 12. In between the filaments 14, and on the top side 18 of the backing layer 12, is an infill material 20 helping to support the filaments 14 in a relatively upright position relative to the backing layer 12. The filaments 14 may be groups of filaments 14 that are individually attached to the backing layer 12, or thick filaments 14 that are split into protrusions at the center of the filaments 14 to give the appearance of numerous individual filaments 14. The infill 20 is further divided into an additional separate zone composed of a rigid and hardened layer 26 having underneath the backing layer 12. This happens either when the whole ballast layer of the infill 20, or portions thereof, have been treated with the hardening acrylic material. As used herein this disclosure, the terms, “rigid and hardened layer” and “hardened and rigid layer” are used interchangeably to refer to a layer that has been treated to be hardened, and becomes hardened to an extent that it makes the treated area or layer rigid. Consequently, applied acrylic material will thereby coat a substantial amount of the ballast layer of the infill 20, such that the ballast layer of the infill 20 eventually becomes hardened. As such, when the hardening material is applied, it will typically coat the granular material in the layer including material on the surface. The synthetic turf system 10 further includes a zone 28 situated above the rigid and hardened layer 26, which constitutes the remainder of the infill 20. These different layers or zones are depicted in FIG. 1, wherein numeral 26 is connected to the rigid and hardened layer, and the horizontal line separating zone 28 from the rigid and hardened layer 26, illustrates the upper top surface of the rigid and hardened layer 26. These elements, altogether, cooperate to form an improved synthetic turf system 10 with optimal aesthetics and increased functional and physical characteristics.

Now, the physical characteristics of the polymeric hardening coating material will be described in greater detail. As previously described, an advantage and premise of using a hardening material has a main purpose of preventing penetration and damage of the backing layer 12. The main chemical properties of the hardening coating material, which can be a stiffening agent physically acts like a “glue” in order to thereby create an elastomeric rigid and hardened layer 26. Another purpose of the hardening coating material is to provide additional strength to the turf by interconnecting with the different components and layers of the turf system 10 as depicted in FIG. 1 via bonding with the filaments 14. Thus, the resultant hardened coating material will preferably be entangled within the filaments 14, such that it locks the filaments 14 to the backing layer 12 as illustrated in FIG. 1. Consequently, the coating helps in remediating the turf system 10 which may otherwise exhibit excessive filament 14 shedding for example, in heavy use areas. As used herein this disclosure, a skilled artisan would understand this as providing an improved “tuft bind” which is basically the magnitude of force required to pull the filaments 14 out of the backing layer 12. The molecular weight of the polymeric coating material may preferably be varied to achieve required and desired characteristics of the final coating surface. The hardening material can for example be a gel or liquid substance (or combination of separate substances that are added), which can be poured, injected, sprayed or otherwise added to coat the infill.

In the preferred embodiment, as depicted in FIG. 1, the use of the hardening coating material, and thus the formation of the rigid and hardened layer 26 is in high-use areas of the turf system 10 having filaments 14 therein. However, in other embodiments, it may also be desirable to use the coating hardening material in areas, wherein the turf system 10 substantially lacks filaments 14, such that the turf system 10 is solely composed of the backing layer 12 and the infill 20. Filaments 14 are made up by a material that is polyethylene, nylon, olefin, or other material used for synthetic turf systems, or a combination thereof. The filaments 14 preferably measure a height that is in a range characterized by at least 1.00″ inches to 4.00″ inches. It is preferred that the backing layer 12 be comprised of a stable, weather resistant material, such as polypropylene, polyester, polyolefins, nylon, a geotextile material or a combination thereof. One having skill in the art will readily understand and appreciate that geotextile materials are rigid materials, in which, when they are used in association with the infill 20, they have the ability to reinforce, or otherwise provide protection to the artificial turf system 10. In some embodiments, the backing layer 12 may also include one or more openings for movement of water, for example.

Preferably, in one embodiment, the hardening coating material is characterized as being an acrylic coating material. In this matter, in an exemplary embodiment, an acrylic emulsion based on the ammonia salt of an acrylic polymer may be used for this purpose. The preferred acrylic emulsion for this application utilizes water dispersible ammonia salts of high molecular weight acrylic polymers to provide for a soft, flexible coating.

When the polymer is contacted preferably with water, the polymer will generally increase in size. After reaching maximum moisture retention, the retained moisture slowly releases from the polymer all depending on the particular conditions being present, such as for example ambient temperature, sunlight, humidity, etc. Typically, the moisture will evaporate from the polymer and will thereby keep the backing layer 12 and the fiber filaments 14 cool.

In other embodiments, the hardening coating material may equally well be a polymeric material like a polyurethane, or any like material that is readily available and known to one having ordinary skill in the art that will ultimately provide similar chemical surface properties when eventually being in a hardened polymeric state. In any of these embodiments, the coating material should preferably be water-based, wherein the water-based hardening material is cured by coalescence.

As such, in theory, these may advantageously include any thermosetting polymers that do not melt when heated, or polymers exhibiting characteristics akin to the foregoing properties. As used herein this disclosure, the term “thermosetting polymer” refers to a polymer material that cures or hardens irreversibly.

In one embodiment, the hardening coating material may be porous, such that water drainage is provided.

In another embodiment, the hardening coating material may equally take the form of being in a non-porous state. As used herein this disclosure. “porosity” refers to whether a material has spaces or holes through which liquid or air may be allowed to pass.

Now without being bound by theory, the method of making a synthetic turf field by using the hardening coating material will be explained in greater detail still referring to FIG. 1.

In accordance with the preferred embodiment, the method is initiated by first installing the artificial turf field comprising a flexible backing layer 12, an infill 20 and a plurality of grass-like filaments 14 attached to the flexible backing layer 12. The filaments 14 are operatively attached to the backing layer 12 via any number of means known to one of ordinary skill in the art. For example, the filaments 14 may be knitted, woven, or tufted into the backing layer 12, and as such, leaving the top portion 22 of the filaments 14 above the top side 18 of the backing layer 12, and the bottom portion 24 of the filaments 14 below the bottom side 16 of the backing layer 12. Thereafter, the bottom portion 24 can be further secured in place using known mechanisms such as but not limited to the use of an adhesive or by stitching means.

Generally, the filaments 14 are secured into the backing member 12 in generally straight and parallel rows to fill the void between the rows (See FIGS. 1-2).

The infill material 20 is placed on the top side 18 of the backing member 12 and in between the filaments 14. The infill material 20 can comprise any number of combinations of conventional particulate material, including hard particles, resilient particles, and combinations thereof. Some typically used hard particulate material includes, such as, but not limited to sand, rock, hard and heavy plastics and typical resilient particulate materials may advantageously include rubber (e.g. including cryogenic), cork, styrene, calcined clay, used tires, neoprene, silica sand or the like materials. One of ordinary skill in the art will realize that any other granular materials akin to the ones mentioned can equally be used to make up the infill 20. In a preferred embodiment, the turf system implements a technique, in which, there are rows of spacing between rows of fibers. The rows of spacing are filled during the installation process with the infill 20, and when installed, provide better foot traction.

Subsequent to installing the synthetic turf field, thereafter, the ballast layer of the infill 20 is applied onto the synthetic turf field. One of ordinary skill in the art will know that the ballast layer of the infill 20 may preferably be made up by sand, rubber, rock, plastics, cork, styrene, calcined clay, used tires, neoprene, a combination thereof, other materials or any granular materials akin to the ones mentioned. This is then followed by applying the hardening polymeric coating material into the ballast layer of the infill 20, or by treating portions of the ballast layer of the infill 20. In some embodiments, the water-based polymeric coating material may be a one component or multi-component material. Thus, in one example, a skilled artisan would know that the application of the hardening coating material can be undertaken by pouring it over the ballast layer of the infill 20, as the consistency of the coating material prior to hardening is in a substantially viscous liquid solution state. This advantageously enables the protective layer of the coating material to be formed in situ after hardening. Thus, as used herein this disclosure, the term, “in situ” refers to the hardening of the coating material taking place in the reaction mixture of the liquid solution after being poured. As such, the hardening coating material is then poured into the ballast layer of the infill 20, for example, immediately upon being admixed prior to complete polymerization and before hardening has taken place. However, one of ordinary skill in the art would appreciate that any method such as spraying, injecting, dipping, or other techniques of applying the hardening coating material over the ballast layer of the infill 20 are also contemplated, so as long as the physical state of the coating material allows it to be applied using the foregoing methods. A skilled artisan will similarly realize that the time it would take for the solution to harden and function as a coating layer may depend on a plurality of chemical and physical factors like the identity of the material being used, the amount of the material and the volume of the water being used, the temperature, humidity, sunlight, whether the solution has any cross-linking agents, etc.

Once the coating material has been poured, it will subsequently be allowed to diffuse through the synthetic turf system 10. The hardening material may be added in such a way that the hardening material can reach and bind to the backing layer 12. The method is finally concluded by applying sand or rubber or a combination thereof constituting the remainder of the infill 20 on top of the formed rigid and hardened layer 26, thereby creating the final zone 28.

As an alternative to the method described above, materials that make a ballast layer may be premixed with the hardening coating material and the mixture may be squeezed or poured as a low viscosity paste or slurry that has flow characteristics. The paste or slurry is then allowed to cure or harden. As such, a hardened layer containing a mixture of ballast materials and the hardening coating material is formed to protect the synthetic turf system. This techniques allows for adding the mixture to form the ballast layer, which hardens as opposed to adding the material for the ballast layer and then adding the hardening agent to the that layer.

As part of the installation system, the characteristics of the turf structure, as a whole, is evaluated and the structure is designed to match the desired field performance by compensating, or adjusting the material in the overall structure. For example, the added stiffness of the lowest layer can be compensated by using a softer or harder material or a higher depth of material. This will ultimately have a potential impact on the Coefficient of Restitution. The Coefficient of Restitution is defined, as for example, the velocity that a baseball will have after impact with the surface of the synthetic turf system 10 divided by the velocity of the baseball prior to impact with the surface. Thus, the formed rigid and hardened layer 26 above the backing layer 12 will potentially provide an increase in the Coefficient of Restitution of the turf surface. In consequence of providing this increase, it will result in an overall improvement of the turf field. This is due to the fact that the Coefficient of Restitution is a key performance driver in such applications, like for example, baseball infields.

It should be generally understood that a backing layer 12 refers to the backing used in manufacturing artificial turf.

FIG. 2 depicts the above-described method of making the synthetic turf field with the hardening polymeric coating material, wherein underneath the filaments 14, the uppermost zone 28 is depicted. Further below zone 28, the rigid and hardened layer 26 created by the hardened polymeric coating material is also depicted in FIG. 2.

In yet other preferred embodiments of the present invention, there is still contemplated a synthetic turf system 10 having a hard protective layer within the backing layer 12. It should be understood that this is advantageously achieved by the application of an easily wetting and absorbing layer of a felt material. The felt layer would be understood as preferably being composed of a fiber material. This may cause the constituent fibers making up the backing layer 12 to press and mat together, so as to form a stable backing layer 12 preferably with minimal opening of the weave fabric. It should be noted that the backing layer 12 may be composed of at least three layers, wherein the filaments 14 are tufted through all three layers together. As such, one layer of the felt is inserted, and is thereby subsequently sandwiched between at least two layers of the backing layer 12, thereby creating the middle felt layer. A wetting is then performed, in which, the polypropylene top side of the backing layer 12 undergoes treatment by application of a multi-part epoxy coating. In accordance with the preferred embodiment, the multi-part epoxy material may preferably be composed of a one hundred percent solids, semi-flexible multi-component epoxy coating. Additionally, the multi-component epoxy coating is formulated, such that it can withstand degradation, and is further resistant to hydrolysis, for example e.g., moisture induced degradation. The multi-part epoxy may contain two different polymeric epoxy chemical components. A skilled artisan will know that the two epoxy components may be mixed preferably in a 1:1 ratio, thereby having equal amounts of each chemical component. In other embodiments, they may equally be mixed in other ratios as well. One of ordinary skill in the art will further appreciate and understand that epoxy materials are characterized as having epoxide functional groups, which are basically cyclic three-atom ether reacting groups. Further, epoxy resins are thermosetting polymers capable of forming tight cross-linked polymer structures, which are known to exhibit increased toughness and strength, strong adhesive capability and low shrinkage after curing at room temperature. Preferably, the multi-part epoxy material will be injected onto the topside 18 of the backing layer 12, which may be constructed from polypropylene, a geotextile material or a combination thereof, as already previously explained. One having skill in the art will know that this can be achieved, by for example using e.g., a caulking gun, or any other like apparatus that allows for the easy and seamless injection of the multi-part epoxy material. Although, the multi-part epoxy material is preferably injected, any other means of applying the multi-part epoxy without further compromising its downward diffusion through the backing layer 12 may be applicable in this matter. As such, once the turf surface has completed tufting, the polypropylene top side of the backing layer 12 is treated with the multi-part epoxy material on-site at the point of installation of the synthetic turf system 10. Thus, following diffusion of the multi-part epoxy material through the backing layer 12, the treatment results in the backing layer 12 being epoxied to at least the middle felt layer of the backing layer 12. In other words, once the multi-part epoxy material wets the middle felt layer, and the multi-part epoxy has eventually cured, the middle felt layer is thereby stabilized by the hardened multi-part epoxy. Therefore, this treatment results in a backing layer 12 that no longer exhibits the characteristics of having a substantially open weave fabric. In essence, this treatment further provides the advantage of stabilizing the backing layer 12. The polypropylene fibers making up the backing layer 12 would no longer be spread apart, when for example e.g., punctured with a sharp object. This is due to the added middle felt layer subsequently having undergone treatment with the multi-part epoxy material. Finally, as already explained previously, one having skill in the art will realize that also in this embodiment, the synthetic turf system 10 may potentially be treated with an infill layer 20 lying above the backing layer 12, comprising infill material in between the filaments 14 of the turf system 10.

In preferred embodiments, implementing the hardened felt embodiment is provided without hardening the infill material, but combinations are possible.

FIG. 3A depicts yet another embodiment of the synthetic turf system 30 of the present invention. The synthetic turf system 30 may comprise a backing layer 35 comprising a felt layer 40 and a backing sheet 43. The system 30 includes an infill layer 45 lying above the backing layer 35 comprising infill material, and a plurality of grass-like artificial filaments 50 attached to the backing layer 35 and extending upward from the backing layer 35 over the infill layer 45. The backing layer 35 may have a top surface 36 on which the infill layer 45 lies on and a bottom surface 37 that is opposite to or away from the top surface 36. The bottom surface 37 is also further away from the infill layer 45 compared to the top surface 36. The backing sheet 43 may have only one single layer or multiple layers. The felt layer 40 or the felt 40 may be made of, for example, natural fibers (e.g., coir, cotton, wool, and silk), synthetic fibers (e.g., acrylic, polyester, rayon, and viscose), or any combinations thereof. The felt layer 40 may also be made of felt-like materials. Felt-like materials may refer to materials that exhibit similar characteristics to the felt 40. These characteristics may include the amount of liquid the material can filter or allow to pass through per a certain time such as one minute (or the porosity of a material), the number of weaves or threads per an area such as in an 1-inch by 1-inch area, a characteristic that can effectively wick a multi-part epoxy (described below), a characteristic that can allow a multi-part epoxy to infiltrate the felt layer evenly so the amount of the multi-part epoxy is consistent in the felt layer after infiltration is complete, and/or a characteristic that can render the surface of the felt layer from which the multi-part epoxy infiltrates to be flat and uniform after infiltration is complete. The term felt-type material is sometimes used herein as more general term to refer to felt material (e.g., natural fiber and synthetic fiber) and other material that is substantially similar in characteristics (e.g., felt-like material) to the felt 40. The felt layer 40 may also be substituted with needle punched fiber lock weave (FLW) or a needle punched FLW layer or similar material (e.g., material have similar wicking and porosity characteristics). The backing sheet 43 may be a sheet that is known to one with ordinary skill in the art to serve as a base for supporting the filaments 50. The filaments 50 may be attached to the backing layer 35 by tufting through the backing layer 35.

The felt 40 may lie on or be attached to either a top surface 38 or a bottom surface 39 of the backing sheet 35. The bottom surface 37 and the bottom surface 39 are the same surface. FIG. 3A illustrates the felt 40 lying on the top surface 38. When the felt 40 lies on the top surface 38, the felt 40 is sandwiched between the infill layer 45 and the backing sheet 43. The felt 40 is preferably in physical contact with the top surface 38 but the felt 40 may also be in direct contact with the top surface 38 if an additional member is employed between the felt 40 and the backing sheet 43. Moreover, regardless whether the felt 40 is in direct or indirect contact with the backing sheet 43, the felt 40 may also be configured and/or lied on the backing sheet 43 without covering the entire top surface 38 as shown in FIG. 3B and FIG. 3C or the entire top surface of the additional member if one is employed. In other words, the felt 40 may be configured and/or lied on the backing sheet 43 with breaks or openings as long as such a configuration does not impede the performance of the synthetic turf system, the attachment of the filaments 50 to the backing layer 35, or the protection offered by the hardened epoxy. The top surface of the additional member refers to the same top surface as the top surface 38 of the backing sheet 43 which is the surface closer to the infill layer 45 or to footsteps of players. The felt 40 may also underlie on or be attached to the bottom surface 39 as shown in FIG. 4. In this configuration, the backing sheeting 43 is sandwiched by the infill layer 45 and felt 40. If desired, the felt 40 may not completely cover the bottom surface 39 like the embodiments disclosed in FIGS. 3A-3C. The felt 40 likewise may or may not be in physical contact with the bottom surface 39 depending on whether an additional member is employed between the backing sheet 43 and the felt 40.

The felt may also be attached to one side of the backing sheet and that one side may be either the top surface 38 or the bottom surface 39. To create a synthetic turf system shown in FIGS. 3A-3C, the backing layer may be installed with the felt facing up or toward the infill layer. To create a synthetic turf system shown in FIG. 4, the backing layer may be installed with the felt facing down or away from the infill layer. As such, although FIG. 3 shows that the surface 38 contacts the felt 40, that surface 38 may also be the surface 39. Although FIG. 4 shows that the surface 39 contacts the felt, that surface 39 may also be the surface 38.

The felt 40 and the backing sheet 43 may be attached to each other, either through the top surface 38 or the bottom surface 39. The felt 40 and the backing sheet 43 may also be attached to each other by tufting filaments 50 through the backing layer 35 where the filaments 50 serve as fasteners. If desired, the two can be fastened via pressure, adhesive, fasteners, sewing, heating, chemical reaction, or other suitable method. The felt 40 and the backing sheet 43 may be attached to each other via any combination of the above methods. In another embodiment, the felt 40 and the backing sheet 43 may be an integrated or single layer as shown in FIG. 3D.

The backing layer comprising the felt layer and the backing sheet may also be treated with the multi-part epoxy coating described above. The multi-part epoxy may be applied to the backing layer to infiltrate and harden the backing layer. In one embodiment, which is shown in FIGS. 5A-5D, the multi-part epoxy 60 may be applied to in a direction 65 such that the multi-part epoxy infiltrates the felt 40 first. The multi-part epoxy 60 may applied to a surface 41 of the felt 40 to infiltrate and harden at different depths. The multi-part epoxy 60 may infiltrate and harden to a depth X which includes only a portion of the felt 40 as shown in FIG. 5A. The multi-part epoxy 60 may also infiltrate and harden to a depth X which includes the entire felt 40 but without any portion of the backing sheet 43 as shown in FIG. 5B. The multi-part epoxy 60 may further infiltrate and harden to a depth Y which includes the entire felt 40 and a portion of the backing sheet 43 as shown in FIG. 5C. The multi-part epoxy 60 may likewise infiltrate and harden to a depth Z which includes the entire felt 40 and the entire backing sheet 43 as shown in FIG. 5D. Preferably, the backing layer 35 illustrated in FIGS. 5A-5D is employed as the backing layer 35 shown in FIGS. 3A-3C. However, the backing layer 35 illustrated in FIGS. 5A-5D may also be employed as the backing layer 35 shown in FIG. 4 by flipping around the backing layer 35 in FIGS. 5A-5D if desired.

In another embodiment, which is shown in FIGS. 6A-6D, the multi-part epoxy 60 may also be applied to in a direction 70 such that the multi-part epoxy infiltrates the backing sheet 43 first. The multi-part epoxy 60 may applied to the surface 38 of the backing sheet 43 to infiltrate and harden at different depths. The multi-part epoxy 60 may infiltrate and harden to a depth A which includes only a portion of the backing sheet 43 as shown in FIG. 6A. The multi-part epoxy 60 may also infiltrate and harden to a depth B which includes the entire backing sheet 43 but without any portion of the felt 40 as shown in FIG. 6B. The multi-part epoxy 60 may further infiltrate and harden to a depth C which includes the entire backing sheet 43 and a portion of the felt 40 as shown in FIG. 6C. The multi-part epoxy 60 may likewise infiltrate and harden to a depth D which includes the entire backing sheet 43 and the entire felt 40 as shown in FIG. 6D. Preferably, the backing layer 35 illustrated in FIGS. 6A-6D is employed as the backing layer 35 shown in FIG. 4. However, the backing layer 35 illustrated in FIGS. 6A-6D may also be employed as the backing layer 35 shown in FIGS. 3A-3C by flipping around the backing layer 35 in FIGS. 6A-6D if desired

In either FIGS. 5A-5D or 6A-6D, the epoxy treatment may occur prior to dispersing the infill layer on the backing layer. The multi-part epoxy may be applied to the backing layer via injection, pouring, brushing, dipping, spraying, or any other suitable method. The multi-part epoxy may for example be in a liquid or slurry form when applied to the backing layer. The cure rate and/or the viscosity of the multi-part epoxy may be manipulated to maximize infiltration, dispersion, and production time. When the backing layer in either FIGS. 5A-5D or FIGS. 6A-6D is employed in a synthetic turf system, the infill layer on the backing layer may further be treated with the hardening coating material described above.

FIGS. 7A-7G depict to an embodiment of a method 700 of manufacturing a synthetic turf system of the present invention. The method 700 may comprise forming a backing layer 35 by providing a felt layer 40 and a backing sheet 43 together (FIG. 7A) (e.g., rolled out during manufacturing of the turf), tufting a plurality of grass-like artificial filaments 50 through the backing layer 35 (FIG. 7B), flipping over the backing layer 35 with the filaments 50 such that the felt layer 40 faces the direction in which a multi-part epoxy 60 is applied (FIG. 7C), applying the multi-part epoxy 60 to the backing layer 35 with filaments 50 (FIG. 7D), hardening the multi-part epoxy 60 in the backing layer 35 (FIG. 7E), flipping over the backing layer 35 with hardened multi-part epoxy 60 (FIG. 7F), and dispersing an infill layer 45 on the backing layer 35 with hardened multi-part epoxy 60 (FIG. 7G). FIG. 4 may be a synthetic turf system manufacturing according to the method described in FIGS. 7A-7G.

The flipping steps shown in FIGS. 7C and 7E may be omitted if the multi-part epoxy 60 and the infill layer 45 can be applied to the backing layer 35 without flipping the backing layer 35 and/or if the multi-part epoxy has a viscosity and cure rate that can adhere to the backing layer 35 without flipping. The step of FIG. 7E and the step of 7F may be occur in a reversed order such that the backing layer 35 containing the multi-part epoxy 60 is flipped first before hardening the multi-part epoxy 60 in the backing layer 35. The multi-part epoxy 60 may infiltrate in one of the manners described in FIGS. 5A-5D. The infill layer 45 is dispersed on backing sheet 43 of the backing layer 35 or is dispersed on the backing layer 35 in a manner such that the backing sheet 43 is closer to the infill layer 45 and the felt layer 40 is further away from the infill layer 45.

Since numerous modifications and changes will readily be apparent to those having ordinary skill in the art, it is not desired to limit the invention to the exact constructions as demonstrated in this disclosure. Accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention.

Thus, for example any sequence(s) and/or temporal order of steps of various processes or methods (or sequence of system connections or operation) that are described herein are illustrative and should not be interpreted as being restrictive. Accordingly, it should be understood that although steps of various processes or methods or connections or sequence of operations may be shown and described as being in a sequence or temporal order, they are not necessarily limited to being carried out in any particular sequence or order. For example, the steps in such processes or methods generally may be carried out in various different sequences and orders, while still falling within the scope of the present invention. Although a specific synthetic turf system has been described herein this disclosure, a broader invention that would include some elements are also contemplated herein this disclosure.

Although the present invention has been described and illustrated herein with referred to preferred embodiments, it will be apparent to those of ordinary skill in the art that other embodiments may perform similar functions and/or achieve like results. Thus, it should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for one another in order to form varying modes of the disclosed invention. Many different embodiments such as variations, adaptations, modifications, and equivalent arrangements will be implicitly and explicitly disclosed by the embodiments described herein, and thus fall within the scope and spirit of the present invention, so as long as all the desired inherent technical features and attributes are not lost.

It should also be understood that the individual components of the turf system 10 in the Figures may not necessarily have been drawn to a correct scale. As such, due to the reason that the Figures are only for illustrative purposes, the comparable sizes of the individual components of the artificial turf system 10 should not be limited and construed to be exactly what is viewed in the Figures. Thus, the length or height of the backing layer 12, the rigid and hardened layer 26, or the infill 20 may be shorter, longer, higher or lower respectively. Additionally, the height, width and the thickness of the plurality of filaments 14 may vary amongst each other, such that some of the filaments 14 may be higher, lower, wider or thicker respectively than the other filaments 14 as depicted in FIG. 2.

It should be understood that it is contemplated that described processes can be implemented in a different order or involve removing or adding steps. It is also contemplated that different features can be combined together even they may not have been described close to each other in the text.

Thus, the scope of the embodiments of the present invention should be solely determined by the appended claims and their legal equivalents rather than by the Figures. 

What is claimed is:
 1. A synthetic turf system comprising: a backing layer comprising a flexible backing sheet and a felt layer formed from a felt-type material, wherein the backing layer contains a hardening agent that is hardened to protect the backing layer from damage; and a plurality of grass-like artificial filaments attached to the backing layer, wherein the artificial filaments extend upward from the backing layer.
 2. The synthetic turf system of claim 1 comprises the felt layer being a layer that is hardened with a multi-component epoxy.
 3. The synthetic turf system of claim 1 wherein the felt layer is adjacent to the backing layer, and further wherein the backing layer contains a multi-part epoxy that has hardened at least a portion of the felt layer to protect the backing layer from damage; and further wherein the synthetic turf system further comprises an infill layer lying above the backing layer comprising an infill material wherein the plurality of grass-like artificial filaments attached to the backing layer extend upward from the backing layer over the infill layer.
 4. The synthetic turf system according to claim 3, wherein the felt layer is sandwiched between the infill layer and the backing sheet.
 5. The synthetics turf system according to claim 4, wherein the felt layer is on the backing sheet without completely covering the backing sheet.
 6. The systematic turf system according to claim 4, wherein the multi-part epoxy is hardened to a depth including a portion of the felt layer.
 7. The system turf system according to claim 4, wherein the multi-part epoxy is hardened to a depth including the entire felt layer but without any portion of the backing sheet.
 8. The system turf system according to claim 4, wherein the multi-part epoxy is hardened to a depth including the entire felt layer and a portion of the backing sheet.
 9. The system turf system according to claim 4, wherein the multi-part epoxy is hardened to a depth including the entire felt layer and the entire backing sheet.
 10. The system turf system according to claim 3, wherein backing sheet is sandwiched between the infill layer and the felt layer.
 11. The systematic turf system according to claim 10, wherein the multi-part epoxy is hardened to a depth including a portion of the backing sheet.
 12. The system turf system according to claim 10, wherein the multi-part epoxy is hardened to a depth including the entire backing sheet but without any portion of the felt layer.
 13. The system turf system according to claim 10, wherein the multi-part epoxy is hardened to a depth including the entire backing sheet and a portion of the felt layer.
 14. The system turf system according to claim 10, wherein the multi-part epoxy is hardened to a depth including the entire backing sheet and the entire felt layer.
 15. A method for manufacturing a synthetic turf system comprising: forming a backing layer by attaching a felt layer and a backing sheet together; tufting a plurality of grass-like artificial filaments through the backing layer; flipping over the backing layer with the filaments such that the felt layer faces the direction in which a multi-part epoxy is applied; applying the multi-part epoxy to the backing layer with filaments; hardening the multi-part epoxy in the backing layer; flipping over the backing layer with hardened multi-part epoxy; and dispersing an infill layer on the backing layer with hardened multi-part epoxy.
 16. A synthetic turf surface comprising: a flexible backing layer comprising a middle felt layer, wherein the middle felt layer is inserted between at least two layers of the backing layer, and further wherein the flexible backing layer contains a two-component epoxy that is hardened to protect the backing layer from damage; an infill layer lying above the backing layer comprising infill material; and a plurality of grass-like artificial filaments attached to the backing layer, wherein the artificial filaments extend upward from the backing layer over the infill.
 17. The synthetic turf surface of claim 16 comprises the felt layer being a layer that is hardened with the two-component epoxy. 